Caulk removing device and associated methods of manufacture and use

ABSTRACT

The present invention provides a removal device or tool for eliminating cured beads of caulk or the like from joints associated with two or more intersecting planar surfaces. The removal device or tool includes a handle portion, an elongated shaft portion attached to the handle portion, the elongated shaft portion comprising a bend at a first predetermined angle, and an end angle portion attached to the elongated shaft portion, the end angle portion comprising two planar surfaces intersecting at a second predetermined angle, wherein the two planar surfaces are each selectively sharpened on one end. The removal device or tool provides a scraping, lifting, and removal function via a forward motion, optionally provides a cutting and removal function via a backward motion, and is adapted to provide a brush attachment to further clean a surface before application of new caulk or like viscous material to the joint.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present non-provisional patent application claims the benefit of priority of U.S. Provisional Patent Application No. 60/646,283, filed Jan. 24, 2005, and entitled “CORNER CAULK REMOVER,” which is incorporated in-full by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to the field of devices and tools for removing cured beads of caulk or the like from joints. More specifically, the present invention relates to a device or tool for removing cured beads of caulk or the like from joints associated with two or more intersecting planar surfaces, providing a scraping, lifting, and removal function via the use of the device or tool in a forward motion, optionally providing a cutting and removal function via the use of the device or tool in a backward motion, and providing the adaptability to include a brush attachment or the like to further clean a surface before application of new viscous caulk or like to the joints.

BACKGROUND OF THE INVENTION

Caulk, or a similar viscous material, is typically used to provide a durable seal between two or more intersecting planar surfaces, such as a bath tub and an adjacent tile wall, a bathroom or kitchen counter top and an adjacent wall, or the exterior side of a window frame and an adjacent exterior wall, in order to prevent water and/or air from entering the gap between the two or more intersecting planar surfaces. Under certain circumstances, existing lines of caulk in a joint may become visibly deteriorated, or may no longer properly serve their function as a sealant against unwanted water and/or air. When this occurs, removal of an existing line of caulk is undertaken as a maintenance procedure prior to applying a fresh line of caulk.

In the prior art, a number of devices and tools are disclosed for facilitating the removal of caulk or the like from joints. Commonly used is a utility knife for the purposes of cutting and scraping the cured caulk from a joint. In addition to the various forms of utility knives used to provide this function, various scrapers, gougers, and chisels are also used to remove cured caulk from a joint. For example, a user might take a utility knife to cut into a cured bead of caulk. A gouging or chiseling tool might then be used to separate the caulk from the planar surfaces comprising the joint. Finally, a scraping tool might be used to scrape residual caulk from the surfaces.

Use of any one of these devices or tools, or a combination of them, may, in fact, provide for the removal of caulk from a joint. However, while such devices and tools may be suitable for their particular purposes, these devices and tools do not provide for the efficient and quick removal of caulk or the like in the same manner as the device or tool of the present invention. Therefore, a need exists for a caulk removing device or tool (hereinafter a “corner caulk remover”) and an associated method of use for eliminating cured beads of caulk or the like from joints, providing a scraping, lifting, and removal function via the use of the device or tool in a forward motion, optionally providing a cutting and removal function via the use of the device or tool in a backward motion, and providing the adaptability to include a brush attachment or the like to further clean a surface before the application of new caulk or like viscous material to the joint.

These and other problems exist. Previous attempts to solve these and other problems include the following, by way of example:

U.S. Pat. No. 6,035,536, issued to Dewberry on Mar. 14, 2000, discloses a hand-held tool for the removal of a cured bead of caulk, sealant, or other previously fluent material from a joint between substantially perpendicular surfaces. The tool includes an elongate handle with two working heads. The primary working head at one end of the longitudinal axis of the handle features a chisel-like point angled down from the upper face of the handle and extending between two symmetrical flanking planes which are acutely angled to each other and also spread from the body of the handle. The planes are beveled to form sharp edges for scraping surfaces during an operation to remove a bead while the chisel-like point chisels the body of the bead from the joint. Axially opposite the primary head, the second working head is essentially an angled chisel-like point extended from the upper face of the handle and is used to chisel, pick, or gouge a bead from a joint.

U.S. Pat. No. 4,920,647, issued to Riley on May 1, 1990, discloses a caulk bead removal tool for removing caulk and beading from a groove between spaced side-by-side concrete building panels and includes a handle. A U-shaped mounting bracket is mounted at one end of the handle. Fasteners secure a center bracket leg of the bracket to one end of the handle, and the bracket has a pair of parallel bracket legs extending from opposite ends of the center bracket leg in a longitudinal direction along a longitudinal axis of the handle, but away from the handle. A pair of relatively flat tool steel cutting blades are disclosed. Fasteners secure the blades to the parallel bracket legs. Each of the blades has four bevel-cut edges and four right-angle corners, where said bevel-cut edges meet, with the four bevel-cut edges being arranged in two sets with the edges in each set being disposed in parallel relation. The blades having their bevel-cut sides mounted on the parallel bracket legs in such a way that one of said blades has its bevel-cut side secured in face-to-face relation to the associated bracket leg and the other of the blades has its flat back side secured in abutment with an outside face of the associated parallel bracket leg.

While these patents and other prior art devices and methods have attempted to solve the above-mentioned problems, none have provided for a corner caulk remover which enables quick and efficient removal of caulk or the like in the same manner as the present invention. For example, the prior art does not disclose any benefit or functionality from a caulk removal device or tool that provides the adaptability to include a brush attachment or the like to further clean a surface before application of new caulk or like viscous material to a joint. Additionally, the prior art does not disclose any benefit or functionality from using a device or tool in a backward motion as part of the caulk removal process. Therefore, a need exists for such a device or tool as that of the present invention.

BRIEF SUMMARY OF THE INVENTION

In various exemplary embodiments, the present invention provides a new and useful device or tool for removing caulk or the like from a joint associated with two or more intersecting planar surfaces. The present invention provides functionality from the use of the removal device or tool in both a forward and backward motion. Additionally, the present invention provides functionality by providing a brush attachment or the like to further clean a surface before the application of new caulk or like viscous material to the joint.

In one exemplary embodiment, the present invention provides a device or tool for removing caulk or the like from a joint associated with two or more intersecting planar surfaces, the device or tool including: a handle portion; an elongated shaft portion attached to the handle portion, the elongated shaft portion including a bend at a first predetermined angle, thereby creating a first elongated shaft portion and a second elongated shaft portion disposed at the first predetermined angle to one another; and an end angle portion attached to the elongated shaft portion, the end angle portion including two planar surfaces intersecting at a second predetermined angle, wherein the two planar surfaces are each selectively sharpened on one end. In this embodiment, the device or tool functions whereby the end angle portion of the device or tool, while used in a forward motion, acts to separate and lift a bead of caulk or the like from the two or more intersecting planar surfaces of the joint and advance the bead of caulk or the like onto the two planar surfaces of the end angle portion intersecting at the second predetermined angle, and whereby the end angle portion of the device or tool, while used in a reverse motion, acts to clip the bead of caulk.

In another exemplary embodiment of the present invention, the corner caulk remover further includes a brush attachment or the like with multiple bristles on a top end of the handle portion for brushing away caulk as it is removed from the joint. This provides a user with the ability to further clean a surface before application of new caulk or like viscous material to the joint.

In a further exemplary embodiment of the present invention, the corner caulk remover is made such that the end angle portion attaches to the elongated shaft portion as a socket driver or ratchet would attach to a socket. The elongated shaft portion may attach to the handle portion in a like manner. This allows for a user of the corner caulk remover to replace an existing end angle portion with a new end angle portion as the existing one becomes worn over an extended period of use.

A primary advantage of the present invention is that the corner caulk remover provides a user with the ability to quickly, easily, and efficiently remove existing cured caulk from a joint. The device or tool is designed such that a few forward and backward motions with the device or tool on the desired surface area will effectively remove the existing caulk. Use of the brush attachment or the like provided with the corner caulk remover further cleans and prepares the surface for a new bead of caulk or other viscous material to be placed.

Another advantage of the present invention is that the corner caulk remover provides for the easy removal of the caulk or the like as it is in the process of being removed. As a user makes forward motions with the device or tool along an existing bead of caulk in an effort to remove it, a backward motion effectively clips or tears the bead of caulk from the full length of caulk existing in a joint, thus allowing it to fall out of the way and further allowing the user to continue removing existing caulk.

A further advantage of the present invention is that the corner caulk remover may include a brush attachment or the like at the top end of the handle portion. The user of the device or tool may use the brush portion to brush off excess caulk particles, which are generated from use of the corner caulk removal device or tool, from the joint area.

A still further advantage of the present invention is that the corner caulk remover is used in such a manner that it allows for minimal wall contact, thus protecting the wall from unnecessary and inadvertent scratching or damage. This is a key advantage of this device or tool over the various utility knives, chisels, gougers, etc. that exist in the prior art.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated and described herein with reference to preferred embodiments and examples thereof, in which like reference numbers denote like parts or components, and in which:

FIG. 1 is a front left perspective view of a corner caulk remover according to an embodiment of the present invention;

FIG. 2 is a front right perspective view of a corner caulk remover according to an embodiment of the present invention, the corner caulk remover including an optional brush attachment;

FIG. 3 is a rear right perspective view of a corner caulk remover according to an embodiment of the present invention;

FIG. 4 is a rear right perspective view of a corner caulk remover according to an embodiment of the present invention, the corner caulk remover including an optional brush attachment;

FIG. 5 is a perspective view of a corner caulk remover according to an embodiment of the present invention, the corner caulk remover shown applied against a bead of bathroom caulk for the purpose of removing the bead of caulk from a corner joint.

FIG. 6 is a front perspective view of a corner caulk remover according to an embodiment of the present invention;

FIG. 7 is a back perspective view of a corner caulk remover according to an embodiment of the present invention;

FIG. 8 is a top perspective view of a corner caulk remover according to an embodiment of the present invention; and

FIG. 9 is a front perspective view of a corner caulk remover according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1, a front left perspective view of the corner caulk remover 10 of the present invention is shown. The corner caulk remover 10 includes a handle portion 20 fixedly or removably attached to an elongated shaft portion 30 fixedly or removably attached to an end angle portion 40.

The handle portion 20 is made of a metal, wood, plastic, fiberglass, or a similar substantially rigid material, such that it will securely, either fixedly or removably, hold the elongated shaft portion 30. Preferably, the handle portion 20 is sized and shaped such that it may be comfortably grasped by a user for an extended period of time.

The elongated shaft portion 30 is made of a metal, plastic, or similar substantially rigid material such that it is strong enough to endure pressure from the user while in use removing caulk. Additionally, the elongated shaft portion 30 and the handle portion 20 may be integrally formed as one piece by means of injection molding or the like into a single plastic device, tool, or the like. The components of the corner caulk remover 10 may also be welded together or the like.

The elongated shaft portion 30 includes a bend 32 at a first predetermined angle 34. Thus, the elongated shaft portion 30 includes a first elongated shaft portion and a second elongated shaft portion disposed at the first predetermined angle 34 relative to one another. The bend 32 at the first predetermined angle 34 is shown in FIG. 1 at approximately one-hundred and thirty-five degrees. Although this is an exemplary first predetermined angle 34, other angles may be used in the manufacture of the corner caulk remover 10, as will be readily appreciated by those of ordinary skill in the art. For example, the bend 32 may be at a first predetermined angle 34 of one-hundred and eighty degrees, such that the elongated shaft portion 30 is essentially straight and contains no bend 32.

The end angle portion 40 is made of a metal, plastic, or a similar substantially rigid material, such that it will endure repeated use in removing caulk. The end angle portion 40 includes two planar surfaces 42 intersecting at a second predetermined angle 44, wherein each planar surface 42 is selectively sloped, beveled, sharpened, or includes a cutting edge of a predetermined length such that there is a beveled end 46 at the end of each planar surface 42 comprising the end angle portion 40. In an alternative embodiment of the present invention, each planar surface 42 of the end angle portion 40 is not sloped, beveled, sharpened, and does not includes a cutting edge of a predetermined length. The second predetermined angle 44 shown is approximately ninety degrees. This second predetermined angle 44 may vary, however. It should be noted that approximately ninety degrees is optimal for a corner joint between two intersecting planar surfaces that intersect at approximately ninety degrees. It should also be noted that other angles may be optimal for other applications, i.e. other types of joints.

Referring now to FIG. 2, a front right perspective view of a corner caulk remover 10 is shown. In addition to the handle portion 20, the elongated shaft portion 30, and the end angle portion 40 components, and their various sub-components referenced in FIG. 1, FIG. 2 also includes a brush attachment 22. The brush attachment 22 is used to brush or sweep excess caulk particles from the working area in which caulk is being removed. Use of such a brush attachment 22 further prepares a surface before a new bead of caulk is placed in a joint.

Referring now to FIG. 3, a rear left perspective view of a corner caulk remover 10 is shown. In addition to the components referenced in FIGS. 1 and 2, FIG. 3 illustrates the elongated shaft portion 30 as it is attached to the end angle portion 40. There are various ways in which the elongated shaft portion 30 may be attached to the end angle portion 40. For example, the end angle portion 40 may attach to the elongated shaft portion 30 like a socket is attached to a socket driver or a ratchet. Such an attachment method allows for easily swapping the end angle portion 40 as it may wear over an extended period of use. Additionally, the end angle potion 40 may be permanently attached to the elongated shaft portion 30 by means of welding or the like, including integral formation. In yet another manner, the end angle potion 40, the elongated shaft portion 30, and the handle portion 20 may be fabricated as one piece by means of injection molding into a single plastic device, tool, or the like.

Referring now to FIG. 4, a rear left perspective view of a corner caulk remover 10 is shown. In addition to the handle portion 20, the elongated shaft portion 30, and the end angle portion 40 components, and their various sub-components illustrated in FIGS. 1, 2, and 3, FIG. 4 illustrates a brush attachment 22 attached to the handle portion 20. The brush attachment 22 is used to brush or sweep excess caulk particles from the working area in which caulk is being removed. Use of such a brush attachment 22 further prepares a surface before a new bead a caulk is placed in a joint.

Referring now to FIG. 5, a perspective view of a corner caulk remover 10 is shown applied against a bead of bathroom caulk for the purpose of removing the bead of caulk from a corner joint. FIG. 5 is shown with all of the components of FIG. 1, but is illustrated with the corner caulk remover 10 in actual use removing caulk. The corner caulk remover 10 is shown in use removing caulk from a joint between the planar surfaces of the top surface of a bath tub and an adjacent tile wall. As the corner caulk remover 10 is illustrated, it has been in use in a forward motion such that caulk has moved up the end angle portion 42 such that it is hanging over the back edge of it. As a user next moves the corner caulk remover 10 in a backward motion, the caulk is torn or pulled away from the continuous bead and falls away from the work area and out of the way.

Referring now to FIGS. 6 through 9, a perspective view of a corner caulk remover 10 is shown in each. The corner caulk remover 10 is shown with another embodiment of the handle portion 20. Additionally, the corner caulk remover 10 is shown with beveled ends 46 and beveled edges 48 on each planar surface 42 of the end portion 40. Furthermore, the corner caulk remover 10 is shown with the planar surfaces 42 tapered at the end nearest the handle portion 20 such that the planar surfaces 42 contact the elongated shaft portion 30. While the second predetermined angle 44 is ninety degrees along most of the distance where the two planar surfaces intersect perpendicularly, the second predetermined angle 44 is reduced as the planar surfaces 42 contact the elongated shaft portion 30 of the corner caulk remover 10.

Although the present invention has been illustrated and described with reference to preferred embodiments and examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve similar results. For example, the corner caulk remover may be manufactured in various sizes, with various handles, and with various attachment means used to attach both the handle portion to the elongated shaft portion and to attach the end portion to the elongated shaft portion. All such equivalent embodiments and examples are within the spirit and scope of the invention and are intended to be covered by the following claims. 

1. A device for removing a bead of caulk or the like from a joint associated with two or more intersecting planar surfaces, the device comprising: a handle portion; an elongated shaft portion attached to the handle portion, the elongated shaft portion comprising a bend at a first predetermined angle; and an end angle portion attached to the elongated shaft portion, the end angle portion comprising two planar surfaces intersecting at a second predetermined angle, wherein the two planar surfaces are each selectively beveled.
 2. The device of claim 1, wherein the handle portion further comprises a brush attachment attached to an end of the handle portion.
 3. The device of claim 1, wherein the first predetermined angle is approximately one-hundred and eighty degrees, such that the elongated shaft portion is straight and no bend exists.
 4. The device of claim 1, wherein the first predetermined angle is approximately one-hundred and thirty-five degrees.
 5. The device of claim 1, wherein the second predetermined angle is approximately ninety degrees, such that the two planar surfaces intersecting at the second predetermined angle intersect at a right angle.
 6. The device of claim 1, further comprising an attachment means wherein the end angle portion attaches to the elongated shaft portion in a removable manner.
 7. The device of claim 1, wherein the elongated shaft portion and the handle portion are integrally formed.
 8. The device of claim 1, wherein the handle portion, the elongated shaft portion, and the end angle portion are integrally formed.
 9. The device of claim 1, wherein the wherein the two planar surfaces are selectively sharpened to aid in the caulk removal process.
 10. A device for removing a bead of caulk or the like from a joint associated with two intersecting planar surfaces, the device comprising: a handle portion; an elongated shaft portion attached to the handle portion, the elongated shaft portion comprising a bend at a first predetermined angle; and an end angle portion attached to the elongated shaft portion, the end angle portion comprising two planar surfaces intersecting at a second predetermined angle, wherein the two planar surfaces are each selectively sharpened on one end; wherein the end angle portion of the device while used in a forward motion acts to separate and lift the bead of caulk or the like from the intersecting planar surfaces of the joint and advance the bead of caulk onto the two planar surfaces of the end angle potion intersecting at the second predetermined angle, and wherein the end angle portion of the device while used in a reverse motion acts to clip the bead of caulk.
 11. A method for manufacturing a device for removing a bead of caulk or the like from a joint associated with two or more intersecting planar surfaces, the method comprising: providing a handle portion; providing an elongated shaft portion attached to the handle portion, the elongated shaft portion comprising a bend at a first predetermined angle; and providing an end angle portion attached to the elongated shaft portion, the end angle portion comprising two planar surfaces intersecting at a second predetermined angle, wherein the two planar surfaces are each selectively beveled.
 12. The method of claim 11, further comprising attaching a brush attachment to an end of the handle portion.
 13. The method of claim 11, wherein the first predetermined angle is approximately one-hundred and eighty degrees, such that the elongated shaft portion is straight and no bend exists.
 14. The method of claim 11, wherein the first predetermined angle is approximately one-hundred and thirty-five degrees.
 15. The method of claim 11, wherein the second predetermined angle is approximately ninety degrees, such that the two planar surfaces intersecting at the second predetermined angle intersect at a right angle.
 16. The method of claim 11, further comprising providing an attachment means wherein the end angle portion attaches to the elongated shaft portion in a removable manner.
 17. The method of claim 11, wherein the elongated shaft portion and the handle portion are integrally formed.
 18. The method of claim 11, wherein the handle portion, the elongated shaft portion, and the end angle portion are integrally formed.
 19. The method of claim 11, further comprising selectively sharpening the two planar surfaces to aid in the caulk removal process. 